sustainable materials manufacturing · sustainable materials & manufacturing ... moon et al,...

ORNL is managed by UT-Battelle for the US Department of Energy

SUSTAINABLE

MATERIALS

&

MANUFACTURING

Opening doors into next-generation sustainable practices in

manufacturing

Soydan Ozcan

2 Presentation_name2 Presentation_name

Disruption in Additive Manufacturing: Bio-BAAM and Biodegradability

Composite Materials Recyclability, Challenges and Opportunities

&


Towards a Green Bio-economy via Innovative Bio-manufacturing: Unlocking the Potentialgg the Potential

Developing Bio-economy: What is at stake?

1) Reducing dependence on fossil resources andaddressing climate change

2) Increasing the resilience, sustainability andproductivity of primary production systems and the food chain

3) Building competitive bio-based industries and manufacturing in US, particularly in rural areas

4) Moving towards a zero-waste society


• Fuel efficient car parts

• Bullet-proof suits

• Flexible displays and batteries

• Packages, building materials

• Furniture, electronics

• Food product

• Cosmetics

• Special papers

• Paper coating

• Flexible batteries

Three Main Mission in Bio-Manufacturing

1 Value Added Forest Products

5 Presentation_name

Redefining biorefinary:Develop value added byproducts from Biorefineries

• We import 49% of the petroleum used.• We send close to $1billion per day overseas to buy oil.

5 Presentation_name

2


Next Generation Agribusiness

Next Generation Agribusiness ("NGA") is about growing perennial crops and turning those crops into finished

products in the same community.

It combines the two powerful economic drivers of agriculture and manufacturing.

Farm in rural America, just as important, manufacture in rural America

3


Bio-Materials are high in Value chain and pull can come from Manufacturing

Value


Cellulose Fibrils are in many forms and functionality

Microfibril matrix Microfibril

Nanofibril

Nanocrystal

amorphous regions

Parallel stack of cellulose chains

Fiber

Moon et al, Chem Soc Rev, 2011

Adapted from Nutrition Resources, 2006

Dufresne et al, J Appl Polym Sci, 1997

Advantages:Abundant, renewable resource with price stability • compostable •biocompatible • high strength and modulus • lightweight • shear thinning thickener (stable against temperature and salt addition)

2014: Thomas Reuters names nanocellulose as one

of the top 10 technologies that will change the world by

2025.


CNC composite forAnionic Exchange Membrane

RSC Advances, 2015US Patent 9,340,461, 2016

Journal of Materials Chemistry A, 2015

Metal oxide nanoparticlesfrom CNF template

3D-printed thermoset fromcellulose/epoxidized

soybean oil

Patent Appl. No. 62/180,181 2016

OHOHOH

OOO

Si NH2

SiO

O ONH2

Interfacial engineering toimprove mechanical properties

Carbohydrate polymers, 2015

Ozcan GroupResearch in

Nanocellulose

3D-printing thermoplasticwith cellulosic fiber and PLA

NanoToday 3: 417-420 (2015)

10 Presentation_name1

0

20

40

60

80

Neat-ABS Neat-PLA 25%CNF-ABS 40%CNF-PLA 30%CF-ABS Al 6061-0 Al 6061-T4

Spec

ific

Stre

ngth

(N.m

/g)

0 Presentation_name

40%CNF-PLA• ~93% of specific strength of Aluminum 6061-T4 alloy.

• Stronger and lower cost than CF-ABS composite

• 100% BIO• 40%CNF-PLA: 0.4x$2/lb + 0.6x$3/lb = $2.6/lb

• 30%CF-ABS: 0.3x$12/lb + 0.7x$3/lb = $5.7/lb

$2.6 / lb

$5.7 / lb

~93%


Materials solutions are most of the time in composites

High Mechanical

High Tg Polymer

Process temp is lower than 200C

Printable

High Volume

Low Cost

Biodegradable compostable

Bio-derived

Printable


Out of Oven Process - Reduced Curl Parts

13 Presentation_name111311133333333333333111313333313333333333333333133333333313333333333333 PPrPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP eesenennnntataaaatattttitiiittttttttiiititiittttttittitiittiiiiitittiiiittttitiiiiiiitiiioononoonnnnnononononoo n_n_n_nnnnnnnnnnnn_________ amamamamammmmmamamammaamammammmmamammmaa eeeeeeeeeeeeeeeee

BAAM-printing of Bamboo with PLA


BAAM-printing of 20% Bamboo fiber-

PLA system


Neat Bio-Based Polymer Feedstock• Non-uniform extrusion

• Significant curlingNeeds modification!!!


BAAM-printing of 20% Flax fiber-PLA system

17 Presentation_name17 name

Shop architect’s design is this year’s winner of the Panerai Design Miami/ Visionary Award

PrPrPrPrPrPrPrPrPrPrPPrPrPrPrPrPrPrPrPrPreseseeseseseseeseseseseseseeseseeesesenenenenenennneeeentttttattttatttttttattaationononononnnonononnnnnnnnnnnn nnnnn_nnnnnnnnnnnn

18 Presentation_name18 namePrPrPrPrPrPrPrPrPrPrPPrPrPrPrPrPrPrPrPrPreseseeseseseseeseseseseseseeseseeesesenenenenenennneeeentttttattttatttttttattaationononononnnonononnnnnnnnnnnn nnnnn_nnnnnnnnnnnn


Biomanufacturing: Fully bio-based, sustainable composites for large scale additive manufacturing

• A newly developed fully bio-based, sustainable composite system (bamboo fiber-biopolymer) was for the first time 3D-printed in large scale.

• A contemporary pavilion system was additively manufactured for an architecture expo as a part of a large collaborative project.

• ~10,000lbs biodegradible material was printed at up to a 40lbs/hr rate.

• The developed bio-composite system offers advantages over commonly used carbon fiber-ABS in terms of embodied energy, carbon footprint, cost and end-of life.

additive manufacturingggggg

0

50

100

150

200

250

300

350

Embo

died

ene

rgy

(MJ/

kg)

Filler Polymer

0

5

10

15

20

25

Car

bon

Foot

prin

t (kg

CO

2/kg

)

Filler Polymer

0

2

4

6

8

10

12

14

Cos

t ($/

kg)

Filler Polymer

ENERGY C-FOOTPRINT COST


Addressing Critical Challenges

Five/Ten Year Technical Goals• 25/50% lower carbon fiber–reinforced

polymer (CFRP) cost• 50/75% reduction in CFRP embodied energy • 80/95% composite recyclability into useful

products

Impact Goals• Enhanced energy productivity• Reduced life cycle energy consumption• Increased domestic production capacity• Job growth and economic development

IACMI - National Institute


A Quick QuestionAn aluminum can that is thrown away will still be a can _____ years from now A) 100B) 300C) 500D) 800

www.etsy.com

500


Sustainable Materials & ManufacturingEnd of Life

Products and infrastructure

Landfill Stock

Resource stock

Dissipation

Material

Ore

Excavation

Collection Disposal

Product

1

III ExcavationExcavation

1I

infrastructure

Excavation

Collection

Excavation


Opportunity• In North America, 29 million pounds (~13,200 MT) of carbon fiber waste

estimated going to landfill per year. In the form of

– Pre-preg, primarily aerospace production scrap– Secondary amount is cured production trim– Some pre-preg scrap has to be oven cured prior to landfill– Regulations vary based on constituents in resin system– Adds cost/time burden on composite manufacturers

• It is difficult to estimate amount of end-of life composite


Challenges• Supply Chain, need to know where material comes from and what it

contains (fire retardants, etc), and available in what format– Sorting, Classifying, labeling

• For value added products, higher fiber volume fraction preform, aligned fibers etc. which could be achieved by new methods of preforming

• Development of standard for products will give confidence to designers and end users.

• Today Landfill fee/tax is not a driver for C-fiber recyling in US. However further legislation or banning landfill will drive recycling

• Life Cycle Assessment studies for recycling processes is needed.


Recycling Proposals Received

Automotive component and 3D printed tool both use reclaimed CFApproved

Recycling aircraft components into 3D printed automobilesIn contracting

Automotive component uses CF reclaimed from scrap prepregIn review cycle

Profitably recycling glass and carbon compositesIn review cycle

26 Presentation_name266

Soydan [email protected]

(865) 241-2158

Thank You!

PPrPresesesssesssseenennnnneeenennnennnntatataaaaatttatatatatttatitititiittt ooononnnoonnooo _n_n_nn_nn_ aammammmamammeeeeeee

SUSTAINABLE MATERIALS & MANUFACTURING

27 Presentation_name

Big Area Additive Manufacturing

272222222272727272727272727772222227727727272727727227772727272777277272772727222222727272777772227222227727277727722227222222727272777727277772777222222727277727272727777227272722222727772727227777272777772777772277777722227277777722777722722777272777222277772772777222277777772227772222222227777772222222227777777222227777222222222777 PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPrPPPPPPPPPrPrPPPPPPPrPrPPPPPPPPPPPPPPPPPPrrrrrPPPPPPPPPPPrPrPrPPPPPPPPPPPPrrrPrPrPrPrPrPPPPPPPPPrPrPrPrPPPPPPPPPPPPPPrPrPrPrPrPPPPPPPPPPPPrPPPPPPPPPPPPPPPrPPPPPPPPPPPPPPPPPPPPPPPPPPPreeseeeessesseseseeeeseeesseeeeseeeseeseee eneneneneneneneeeeneneennnenenneneneneeneneneneenenenennnnnenennnenennennenenneneneenenenentttataaatataaaaattatttttttatttttataaaattaaaaaaattataaatttatataaataaaaatatattaataaaaaataaaaaaaaaatttaaaaaaataaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaatataaaaaaaaaaaaaaaaaaattittitititittttttiiititttttittititttttitiiittttttiittttittttttiititttttttttiiittttttttttttttttitittttttttttttttittittttttttttttttttttttttttttttttttttttttttt ooonooonoononnnnnonnonnoonooonnnnnooonoonoooonnonooonnooooooononnononoooooooonooooooononnnnnonnonnnnonononnnnnnonnnoonoooooooononoono n_nnnnnnnnnnnnnnnnnnnnnnnnn_n__nnnnnnnnnn_nnnnnnnnnn_n_nnn_nnnnnnnnnnnnnnnnnnnnn_n_nnnnnnnnnnnnnnn_nnnnn__nnnn_nnnnnnnnnnnnnn_nnnnnnnnnnn_ aaaaaammmmmaammaamaaaaammmmmmmmmaaaammaammmmmmmaaammmammeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee

28IACMI Overview 28IACMI Overview

Composite Materials Recyclability, Challenges and Opportunities

Soydan Ozcan

IACMI- The Composites Institute

09/014/2016, JEC- Knoxville TN


Our Vision and Mission Vision:

Our collaboration of industry, research institutions and state partners is committed to accelerating development and adoption of cutting-edgetechnologies in recycling and re-manufacturing of composites

Mission:

To lead and grow a composite recycling industry that fully diverts fiber scrap and end-of life composite products into value-added productsEconomic: Grow manufacturing and create jobs across the composite industryEducation: Support the training of a workforce prepared for and accomplished in the skills required by the composite recycling industry.Environment: Reduce the amount of composite landfill through re-use in new applications with reduced energy and environmental footprints.


Increasing volume of materials to be recycled in aeronautics


Recycled Carbon Fiber and Value


>Composite Recycling Activities

CRTC

Vartega

Adherent Technology

Materials Innovation

TechCHZ Tech


Driving Forces for Sustainable Materials & Manufacturing

Social

Environmental Economical

SUSTAINABLE

• Growing public concern about environmental issues

• Corporate social responsibility

• Economical viability


Concluding Remarks

• Well recognized that composite recycling needs “market pull” to elevate demand and value, and improve reclamation business case, It is so critical to develop supply chain.

• Achieving Technological barriers in manufacturing technologies yielding product sales, creating confidence in using reclaimed fibers and, most importantly, fund increased R&D into new product areas

• Early manufacturing and development efforts will generate standardization and also process knowledge that feeds new applications/opportunities

35 Presentation_name

Big Area Additive Manufacturing (BAAM)

3333535355555555555535355 PPPPPPPPPPPPPrPrrrrPPPPPrPrPPPPPPPPPPrPPPPrPPPPPPrPPPPPPrPrPrrrrPPPPPrrrPPPPrPrPrrPPrPrPrrPPrPPrPrPPPrPPrPPrPPPPPPPPP eeeeeeeeeeeseeeeseseseeeeeeseeeeeeeeeeeeeeseeseee eeeneneneneentaatatatataatttittititionononnonnn n_n_ ammamameeeee

Conventional AM• Small (< 1 cubic ft)• Slow (< 5 ci/hr)• Expensive (~$100/lb)• Takes days to go through 1 kg spool

– Not exciting for material manufacturersBig Area Additive Manufacturing• Large (> 1000 cubic ft)• Fast (>2500 ci/hr)• Cheap (<$5/lb)• One machine can go through a gaylord in a day

sustainable materials manufacturing · sustainable materials & manufacturing ... moon et al,...

Documents